Freeport-McMoRan’s board approved a $4.5 billion expansion and modernization program for its Bagdad copper and molybdenum operation in northwest Arizona, USA. The brownfield project is designed to maximize its full potential and is expected to more than double Bagdad’s mining and milling rates, providing approximately 115,000 metric tons per day (mt/d) of incremental nameplate processing capacity with potential to increase over time.
This investment would increase annual long-term copper production to more than 400 million pounds per year (lb/y) (incremental production of approximately 225 million lb/y) and molybdenum production to more than 20 million lb/y (incremental production of 12 million lb/y). Freeport said it plans to deploy modern technologies, automation and leverage existing operations to improve Bagdad’s long-term cost position and performance. The expansion would position Bagdad as the second-largest copper mine in the USA, behind Freeport’s Morenci operation, as well as a leading U.S. molybdenum producer and one of the lowest-cost operations in Freeport’s U.S. portfolio.
Freeport President and CEO Kathleen Quirk expressed her excitement over the Bagdad expansion, framing it as an important step in advancing Freeport’s U.S. copper growth strategy. “This low-risk brownfield project builds on Bagdad’s substantial reserve base, long operating history, existing infrastructure and experienced workforce to deliver new U.S. copper and molybdenum production and further strengthen Freeport’s position as America’s Copper Champion,” she said.
The Bagdad mine has operated since 1945 and has a current reserve life exceeding 80 years before considering additional mineral resources. In 2025, Bagdad completed its fleet conversion, becoming the first major U.S. mine with a fully autonomous haulage fleet. The expansion will leverage Bagdad’s established operating history and extensive knowledge of the ore body while incorporating modern technology to strengthen Bagdad’s production profile.
Freeport said it is advancing engineering, procurement planning and early works to support efficient project execution, including a new primary crusher, overland conveyor, water pipeline, power line, mining equipment and related facilities. The project will provide more than 4,000 direct and indirect jobs during construction, along with thousands of long-term opportunities in Arizona. Freeport said it anticipates a construction period of approximately 3.5 years, with initial production targeted in mid-2030.
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